Mitigating rising supply costs with on-site nitrogen generation

11 December, 2024

From food preservation to chemical manufacturing, to electronics’ production - industry uses nitrogen gas extensively for its inert properties, helping to prevent oxidation and combustion.

Yet purchasing supplies of the gas externally can be costly, meaning many manufacturers are turning to their compressed air systems to generate guaranteed-purity nitrogen on site.

Nitrogen generation – how does it work?

Ambient air typically consists of approximately 78% nitrogen, 21% oxygen, and one per cent made up of other gases, including water vapor and carbon dioxide.

Once the ambient air is drawn into the system, it is then compressed to a higher pressure before downstream filters and dryers purify the air to remove particulates and moisture.

The purified air is then directed to a nitrogen generator, using either membrane separation or pressure swing adsorption technologies – effectively separating the nitrogen gas from the other components in the treated air.

The generated nitrogen is then stored in a buffer tank to ensure a steady supply and consistent pressure. Advanced control systems monitor and regulate the purity and flow rate of the nitrogen, ensuring it meets the specific requirements of the application.

One of the key advantages of on-site nitrogen generation is its seamless integration with existing compressed air systems. These systems can be tailored to specific needs, offering precise control over nitrogen purity and flow rates.

Latest advancement in compressed air technology

As compressed air systems continue to improve and evolve, so too does their ability to generate a consistent supply of nitrogen.

Advances in compressor efficiency mean modern machines can produce higher volumes of compressed air with less energy consumption, which coupled with variable speed drive technology, help to deliver the precise volumes of air required.

This in turn means generating nitrogen, as a by-product of the compression process, can be achieved more efficiently too.

Elsewhere, advanced purification methods ensure that the compressed air is free of contaminants before it enters the nitrogen generation system.

The cost-saving benefits of on-site nitrogen production

Eliminates purchase and delivery costs

By generating nitrogen on-site, manufacturers can eliminate the recurring expense of purchasing nitrogen cylinders or bulk liquid nitrogen – and the associated time and expense of scheduling deliveries.

Lower storage costs

On-site nitrogen generation systems only produce nitrogen as it is needed, adjusting production rates in real-time to align with operation needs. This reduces the necessity for large and expensive storage tanks or cylinders and the ongoing management of inventory.

Energy efficiency

As these systems produce nitrogen only when needed, operators can avoid the energy waste associated with overproduction and storage. In addition, on-site systems can be scaled up or down based on demand, ensuring cost-effective nitrogen production.

Reduced downtime

On-site generation ensures a continuous supply of nitrogen, minimising production downtime due to delayed or missed deliveries.

Mitigation from market volatility

Self-generating the nitrogen supply required helps operators mitigate for market fluctuations and price increases associated with a bought-in supply, enabling a more predictable and stable cost structure.

Long-term investment

Long-term operational savings often outweigh the upfront costs of the nitrogen generation equipment, and it is not uncommon to achieve savings in the region of 90 per cent, compared to the cost of bought-in nitrogen cylinders.

By leveraging advanced technologies in air compression and purification, on-site nitrogen generation offers a cost-effective, reliable, and sustainable solution for industries requiring high-purity nitrogen

For more information, please speak to a BCAS member who can assist in this area by emailing enquiries@bcas.org.uk or call 0207 935 2464 or visit:  www.bcas.org.uk

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